Owner s Manual. Model Numbers. Aqua-Hot Motor Coach Heating System Owner's Manual 05/02 AHE S -12 VDC AHE S - 24 VDC

Transcription

1 Owner s Manual Model Numbers AHE S -12 VDC AHE S - 24 VDC

2 OWNER S INFORMATION Owner s Name: Address: City: State: Zip Code: CUT HERE AND MAIL IN Telephone: Coach Model: Coach Date of Purchase: Aqua-Hot Model No: Aqua-Hot Serial No: Please Mail To: Vehicle Systems Warranty Department East Highway 52 Ft. Lupton, CO Vehicle Systems, Inc. Warranty Department East Highway 52 Ft. Lupton, CO 80621

3 TABLE OF CONTENTS 1.0 Overview 2.0 Operating Instructions 2.1 Activating the Aqua-Hot Heating System 2.2 Zone Thermostat(s) Operation 2.3 Using the Domestic Hot Water System 2.4 Using the Engine Preheat System 2.5 Diesel-Burner Operational Flow-Chart 2.6 Precautions 3.0 Maintenance 3.1 Maintenance Schedule 4.0 Winterization 4.1 Domestic Hot Water System 5.0 Troubleshooting SECTION 1: OVERVIEW Aqua-Hot Overview The Aqua-Hot Motor Coach Heating System is an on-board Hydronic Heating System (heating with hot water) that provides a continuous, on-demand supply of domestic hot water, as well as interior zone heating where and when it is needed. Both heating features are accomplished by a unique Diesel-Fired Burner and an AC powered Electric Heating Element (120 VAC). These two heating sources maintain the temperature of the Aqua-Hot's solution of water and antifreeze. In addition, the Aqua-Hot has been designed to preheat the vehicle's engine prior to starting. This feature provides easy engine start-up whenever cool weather conditions are present. Be sure to review Figure 1 for complete component overview. Page 1-1

4 SECTION 1: OVERVIEW Aqua-Hot Overview, continued Zone C Supply Zone A Return Zone B Return Zone B Supply Zone C Return Zone A Supply Expansion Tank Hot Cold Fill / Radiator Cap Thermostat Access Panel VAC Service Input Terminal Board Zone Circulation Pump Engine Preheat Circulation Pump VAC Access Panel Fuse Block I.D Plates Diesel-Burner Head Engine Coolant Supply Diesel Fuel Supply Diesel Fuel Return Pressure-Relief Valve Hot Water Outlet (Domestic Water) Cold Water Inlet (Domestic Water) Engine Coolant Return Zone Relay #C Electric Heating Element Access Panel Diesel-Burner Control Mixer Unit Valve Zone Relay #A Zone Relay #B Figure 1 Page 1-2 SECTION 2: OPERATING INSTRUCTIONS Heat Source Please read the complete Owner s Manual prior to operating your Aqua- Hot Heating System. Also, be sure to fill out and mail in your Owner s Information Card located at the front of this manual. 2.1 Activating The Aqua-Hot Heating System Diesel-Burner Turn the Diesel-Burner Control Switch ON. This procedure will activate the Diesel-Burner and the indicator light located on or near the Switch. Please contact your specific motorhome manufacturer for the exact Diesel-Burner Control Switch location. Allow minutes for the System to reach operating temperature. Please note that the Diesel-Burner is the main heat source for heating both the interior and the domestic hot water. So, be sure to leave this switch ON during normal heating requirements. Electric Heating Element The VAC Electric Heating Element is wired directly into your motorhomes 120 VAC electrical system and is operational whenever VAC power is available. Allow 1-2 hours for the System to reach operating temperature. Please note that the Electric Heating Element will adaquately provide all your heating needs only for low heating demand situations, such as when moderate ambient temperatures exist and/or when there is a low demand for domestic hot water. Page 2-1

5 SECTION 2: OPERATING INSTRUCTIONS Heat Source, continued NOTE: Both the Diesel-Burner and the 120 VAC Electric Heating Element are thermostatically controlled. Either, or both, heating sources will automatically maintain the temperature of the Aqua-Hot's water and antifreeze solution between approximately degrees Fahrenheit. So simply choose how you want to heat your coach/hot water and just leave the Switch(s) (Diesel, Electric, or both) ON. Comfort Control 2.2 Zone Thermostat(s) Operation Interior Room Thermostats Simply adjust each Room Thermostat to the desired temperature. Then whenever a Room Thermostat calls-for-heat the Aqua-Hot s Circulation Pump(s) and Interior Zone Fans will be activated. These devices together will supply warmth and comfort to each interior heating zone. Please contact your specific motorhome manufacturer for the exact Room Thermostat location(s). Bay Thermostat Simply adjust the Bay Thermostat to approximately 40 degrees Fahrenheit. This will prevent freezing of the domestic water storage system. Please contact your specific motorhome manufacturer for the exact Bay Thermostat location. Page 2-2 SECTION 2: OPERATING INSTRUCTIONS Hot Water 2.3 Using the Domestic Hot Water System When the Aqua-Hot is at operating temperature, the domestic water is automatically heated as it is being used. Because the Aqua-Hot does not store any hot water simply open any hot water faucet and a continuous supply of domestic hot water will be present within a few seconds. This hot water feature is continuous and is accomplished by the Aqua-Hot s Mixer Valve and Intergal Domestic Hot Water Heating System. Please note that the Diesel-Burner Control Switch must be ON to get an unlimited supply of hot water (i.e. during showers). Engine Preheat 2.4 Using the Engine Preheat System When the Aqua-Hot is at operating temperature, and the Diesel-Burner and/or the 120 VAC Electric Heating Element Switch(s) is ON, follow these simple instructions: A. Turn the Aqua-Hot's Engine Preheat Switch ON. This procedure will activate the Engine Preheat Circulation Pump. Circulating the engine's coolant through the Engine Preheat System will adequately warm the engine for easy start-ups on cool mornings. Please contact your specific motorhome manufacturer for the exact Engine Preheat Switch location. NOTE: Allow approximately 1 to 2 hours of engine preheating run time. Time will be shortest when the Diesel-Burner Control Switch is ON. Page 2-3

6 SECTION 2: OPERATING INSTRUCTIONS Engine Preheat, continued B. Turn OFF the Aqua-Hot's Engine Preheat Switch whenever engine preheating is not desired. NOTE: The Aqua-Hot's Engine Preheating System acts as a supplemental heating source, in addition to the Diesel-Burner and the 120 VAC Electric Heating Element. While traveling, the engine's heated coolant will automatically pass through the Engine Preheat / Motoraide System, transferring heat into the Aqua-Hot's Heat Tank. This design feature reduces the total operating hours of the Diesel-Burner and the 120 VAC Electric Heating Element. Page 2-4 SECTION 2: OPERATING INSTRUCTIONS Diesel- Burner Component Overview 1. Control Unit 10. Combustion Chamber 2. Motor 11. Heat Exchanger 3. Ignition Coil 12. Exhaust Port 4. Clutch 13. Flame Detection Photocell 5. Combustion Air Fan 14. Fuel Pump 6. Fuel Solenoid Valve 15. Fuel Ports (Supply / Return) 7. Electrode Holder 16. Combustion Air Port (Intake) 8. Ignition Electrodes with Adjustable Shutter 9. Fuel Nozzle Figure 2 Page 2-5

7 SECTION 2: OPERATING INSTRUCTIONS Diesel- Burner Operational Flow-Chart 2.5 Diesel-Burner Operational Flow-Chart Operation sequence once the Aqua-Hot's Diesel-Burner Control Switch is turned ON. The Control Switch's indicator light will illuminate. NOTE: If the Aqua-Hot's Coolant reservoir temperature is approximately 175 degrees Fahrenheit, or higher, the "MOTOR" (#2) will not operate. Only when the temperature has dropped below 175 degrees Fahrenheit will the "VDC CONTROL THERMOSTAT" allow the "MOTOR" (#2) to operate. Simultaneously the "IGNITION COIL" (#3) produces a High Voltage Spark across the "IGNITION ELECTRODES" (#8) which ignites the incoming Air / Fuel mixture. The "MOTOR" (#2) (which turns the "COMBUSTION AIR FAN" (#5) and drives the "FUEL PUMP" (#14)) will begin to run. After approximately seconds the "FUEL SOLENOID VALVE" (#6) opens and fuel is sprayed into the "COMBUSTION CHAMBER" (#10) through the "FUEL NOZZLE" (#9). Once the ignited Air / Fuel mixture (FLAME) is observed by the "FLAME DETECTION PHOTOCELL" (#13), the "IGNITION COIL" (#3) will automatically switch OFF. The combustion process now continues to operate unassisted. Page 2-6 SECTION 2: OPERATING INSTRUCTIONS Diesel- Burner Operational Flow-Chart 2.5 Diesel-Burner Operational Flow-Chart The combustion process will continue to operate in this manner until: A.) The "VDC CONTROL THERMOSTAT", (which senses Coolant Temp.), reaches the preset temperature of approximately 190 degrees Fahrenheit. The "MOTOR" (#2) will continue to run for approximately three (3) additional minutes. This is called the "Purge-Cycle", which cools down the Heater's internal components and purges the "COMBUSTION CHAMBER" (#10) of any residual exhaust gases. NOTE: When the Aqua-Hot's Diesel- Burner is switched OFF by the "CONTROL THERMOSTAT". B.) The Aqua-Hot's Diesel- Burner will automatically turn back ON once the coolant temp. reaches the preset temperature of approximately 175 degrees Fahrenheit. B.) The Aqua-Hot's Diesel- Burner Control Switch is turned OFF. Once the Heater switches OFF, thermostatically or manually, the "FUEL SOLENOID VALVE" (#6) closes, which interrupts the supply of diesel fuel to the "FUEL NOZZLE" (#9). A.) The "MOTOR" (#2) will shut-off once the three (3) minute "Purge-Cycle" has expired. SUMMARY: The Aqua-Hot's Diesel-Burner is operational anytime the operator activates the Diesel-Burner Control Switch to the ON position. The Diesel-Burner will then automatically maintain the temperature of the coolant without any additional involvement from the operator. Page 2-7

8 SECTION 2: OPERATING INSTRUCTIONS Important Information 2.6 Precautions CAUTIONS: The Aqua-Hot's Exhaust is HOT! DO NOT park in areas where dry conditions exist underneath the vehicle, as a fire may result (i.e. dry grassy fields). DO NOT operate the Aqua-Hot s Diesel-Fired Burner inside an enclosed building. Operating the Aqua-Hot Diesel-Burner or the 120 VAC Electric Heating Element without the water and antifreeze solution will cause serious damage to the Heater. The Heater should be switched OFF when refueling. Page 2-8 SECTION 3: MAINTENANCE Upkeep 3.1 Maintenance Schedule Monthly Check the Aqua-Hot's solution of water and antifreeze to ensure that it is at the proper level. Do this by visually checking the coolant level in the Aqua-Hot's Expansion Tank, see Figure 1. This should be checked only when the Aqua-Hot is at operating temperature, HOT. Annually CAUTION: Before cleaning or servicing, disconnect all power supplies. It is ideal to have your Aqua-Hot tuned-up yearly. A tune-up should consist of a Fuel Nozzle and Fuel Filter replacement and a thorough cleaning of the Combustion Chamber, if necessary. This simple tune-up will keep your Aqua-Hot running smoothly throughout the year. This annual tune-up will also allow service personnel to inspect for wear and tear of other components. CAUTION: Operating the Aqua-Hot s Diesel-Burner or the 120 VAC Electric Heating Element without the water and antifreeze solution will cause serious damage to the Heater. Page 3-1

9 SECTION 4: WINTERIZATION Storage 4.1 Domestic Hot Water System The Aqua-Hot's domestic hot water system must be completely drained of domestic water any time the heater is stored where freezing temperatures may be experienced. CAUTION: Not winterizing your Aqua-Hot, when freezing temperatures are present, will result in serious damage to the Aqua-Hot's domestic hot water system. NOTE: The Aqua-Hot can still be used for interior zone heating even if the domestic hot water system has been drained and winterized. Follow the instructions listed below when winterizing the Aqua-Hot s domestic water system: A. Completely drain the fresh water storage tank. NOTE: If your coach is equipped with appliances that use fresh water (i.e. ice makers, water purifiers, etc.) follow the manufacturer's recommendation for winterization. B. Disconnect the domestic water demand pump's suction line from the fresh water storage tank. C. Attach an adequate piece of hose onto the suction side of the domestic water demand pump. D. Place the opposite end of the hose into an adequate supply of FDA approved RV-Antifreeze; approximately 2 gallons will be required. Page 4-1 SECTION 4: WINTERIZATION Storage, continued E. Open/close all interior and exterior water faucets, one at a time, until only pure RV-Antifreeze is present. Perform this procedure for both hot and cold faucets. F. Remove the hose and reconnect the domestic water demand pump's suction line to the fresh water storage tank. G. Disconnect all electrical power supplies to the Aqua-Hot during storage. NOTE: 1. For de-winterization, fill the fresh water storage tank with fresh water. Open/close all interior and exterior water faucets, one at a time, until only clear water is present/visible. CAUTION: If you re disinfecting your potable water system, after de-winterizing, be sure to follow RVIA s Instruction for Disinfection of Potable Water Systems on Recreation Vehicles. These instructions can be found in the ANSI A119.2 Handbook for Recreational Vehicle Standards. To receive a copy of this RVIA Standard, write to: Recreation Vehicle Industry Association, 1896 Preston White Drive, P.O. Box 2999, Reston, VA , or visit the RVIA website at Page 4-2

10 SECTION 5: TROUBLESHOOTING Prior to troubleshooting your Aqua-Hot, be sure to reference Figure 1 for a complete overview of the heating system, and Figure 2 for a complete component overview of the Diesel-Burner. Also, please review Section 2.5 of this manual for details on the Diesel-Burner s operation. Use the following chart when troubleshooting your Diesel-Burner only. Failure Symptom Probable Cause Remedy No Indicator Light on the Diesel-Burner Control Switch or Indicator Light goes Off after 30 sec. Diesel-Burner Control Switch is On, but the Diesel-Burner s Motor does not function, see Figure 2. Diesel-Burner does not respond with the sec. Purge-cycle Diesel-Burner s Combustion Process does not take place. Diesel-Burner s Combustion Process stops after 30 sec. Less than 10 Volts DC to the Aqua-Hot. No Fuel to the Diesel-Burner. Defective Fuel Nozzle. Defective Indicator Light Bulb. Loose Harness Plug Connections at the Control Unit. Open E or F Fuse at the Aqua-Hot. Less than 10 Volts DC to the Aqua-Hot. Defective Diesel-Burner Control Switch or Loose Conn. Less than 10 Volts DC to the Aqua-Hot. Loose Harness Plug Connections at the Control Unit. Open E or F Fuse at the Aqua-Hot. No Fuel to the Diesel-Burner. Defective Fuel Nozzle. Loose Harness Plug Connections at the Control Unit. Less than 10 Volts DC to the Aqua-Hot. Check House Batteries and Charging System. Check Fuel Filter and Fuel System. Replace Fuel Nozzle. Replace Indicator Light Bulb. Check Harness Plug Connections to be secure and in place on the underside of the Control Unit. Replace E or F Fuse. Check House Batteries and Charging System. Replace Switch or Repair Loose Connection. Check House Batteries and Charging System. Check Harness Plug Connections to be secure and in place on the underside of the Control Unit. Replace E or F Fuse. Check Fuel Filter and Fuel System. Replace Fuel Nozzle. Check Harness Plug Connections to be secure and in place on the underside of the Control Unit. Check House Batteries and Charging System. Use the following chart when troubleshooting your 120 VAC Electric Heating Element only. 120 VAC Electric Heating Element does not produce heat, or hot water, when motorhome is plugged into shore power. VAC Breaker is Off or Switch is Defective. Turn VAC Breaker On or replace Switch. Page 5-1 SECTION 5: TROUBLESHOOTING Aqua-Hot Quick Reference Chart COMPONENTS Diesel Control Switch "On" Diesel Control Switch Indicator Light Engine Preheat Control Switch Diesel-Burner Diesel-Burner Diesel-Burner Diesel-Burner Diesel-Burner FAILURE SYMPTOM No Function No indicator light or "Off" after 30 sec. No indicator light Motor is not operating No second prime cycle Ignition Coil will not spark No Combustion Combustion stops after 30 seconds 120 VAC Heating Element No heat / hot water when plugged into shore power Engine Preheat Diesel Engine Remains cold Switch Indicator Light Bulb Diesel Control Switch CHECK OR REPLACE IF NECESSARY Aqua-Hot ("E" & "F") Fuses, Continuity? VDC Voltage Level to Aqua-Hot VDC Wiring and B-Plug Harness Conn. VAC Circuit Breaker Fuel Nozzle Engine Preheat Control Switch Fuel Supply (No Fuel or air leak) Aqua-Hot ("A") Fuses, Continuity? Diesel-Burner C-Plug Harness Conn. Page 5-2

11 WARRANTY POLICY - FOR AQUA-HOT MODELS - Vehicle Systems Inc. warrants the AQUA-HOT Heater, to the original owner, to be free from defects in material and workmanship under design usage and service conditions for a period of two (2) years on parts and labor beginning on the date of purchase of the vehicle. Replacement parts are covered for the remainder of the heating systems warranty or for six months (180 days) which ever is greater. This warranty does not apply to damage or failure of the AQUA-HOT Heater or the vehicle into which it was installed due to improper installation, assembly, maintenance, abuse, neglect, accident, or the use of parts not supplied by Vehicle Systems Inc. Vehicle Systems is not responsible for incidental or consequential damages. The intent of this warranty is to protect the end user of the heating system from such defects, which would occur in the manufacture of the product. The warranty is not intended to protect the end user from problems, which are outside the ability of Vehicle Systems control. To obtain warranty repair authorization or for additional information please contact our Technical Support Department at (8 AM to 5 PM) Mountain Standard Time. OWNER S SERVICE LOG: Date Scheduled Service Service Center

12 (Continued) OWNER S SERVICE LOG: Date Scheduled Service Service Center (Continued) OWNER S SERVICE LOG: Date Scheduled Service Service Center

13 Motor Coach Heating Specialists Manufacturers and Distributors East Highway 52 Fort Lupton, Colorado Fax: Copyright 2002 Vehicle Systems, Inc. All rights reserved LTE-LMA-002

14 AQUA-HOT PARTS MANUAL Parts Manual Model Numbers AHE S -12 VDC AHE S - 24 VDC * Asterick denotes 24 volt model Aqua-Hot Motor Coach Heating System Parts Manual 06/02

15 AQUA-HOT PARTS MANUAL Diesel Burner Parts 2 WPX Control Unit, 12 VDC, DBW , AH/HH/WH 2* WPX B Control Unit, 24 VDC, DBW , AH/HH/WH 3 WPX Bracket, Control Unit, DBW , AH/HH/WH 4 WPX Screw, Fastening, Coil, DBW-2010, AH/HH/WH 5 WPX Coil, Ignition, 12 VDC, DBW , AH/HH/WH 5* WPX Coil, Ignition, 24 VDC, DBW , AH/HH/WH 6 WPX Socket, Ignition Wire, DBW , AH/HH/WH 7 WPX Wire, Ignition, DBW , AH/HH/WH 8 WPX Electrode Boot, Rubber, DBW-2010, AH/HH/WH 10 WPX Shutter, Combustion Air Intake, DBW , AH/HH/WH 11 WPX Screw, Protection Cap, DBW-2010, AH/HH/WH 12 WPX Washer, Star, Protection Cap, DBW , AH/HH/WH 14 WPX Cap, Protection, Motor, DBW-2010, AH/HH/WH 22 WPX Screw, Flange-Blower Housing, DBW-2010, AH/HH/WH 24 WPX A Flange, Motor, DBW-2010, AH/HH/WH 25 WPX Screw, Flange-Motor, DBW-2010, AH/HH/WH 26 WPX Washer, Star, Flange-Motor Screw, DBW , AH/HH/WH 27 WPX Motor, Combustion Air/Fuel Pump, 12 VDC, DBW-2010, AH/HH/WH 27* WPX Motor, Combustion Air/Fuel Pump, 24 VDC, DBW-2010, AH/HH/WH 28 WPX Clutch Half, 6mm, DBW-2010, AH/HH/WH * Asterick denotes 24 volt model Aqua-Hot Motor Coach Heating System Parts Manual 06/02 Page 1-1

16 AQUA-HOT PARTS MANUAL Diesel Burner Parts, continued Page 1-2 * Asterick denotes 24 volt model Aqua-Hot Motor Coach Heating System Parts Manual 06/02

17 AQUA-HOT PARTS MANUAL 35 WPX Harness, C-Plug, DBW-2010, AH/HH/WH 38 WPX Screw, Blower Housing, DBW-2010, AH/HH/WH 39 WPX Washer, Lock, Blower Housing, DBW-2010, AH/HH/WH 40 WPX Housing, Blower, DBW-2010, AH/HH/WH 41 WPX Blower, Combustion Air, w/shaft, DBW-2010, AH/HH/WH 42 WPX Bearing Kit, DBW-2010, AH/HH/WH 43 WPX O-Ring, Blower Casing, DBW-2010, AH/HH/WH 44 WPX A Casing, Blower, DBW-2010, AH/HH/WH 45 WPX Grommet, Blower Casing, Left, DBW-2010, AH/HH/WH 46 WPX Grommet, Blower Casing, Right, DBW-2010, AH/HH/WH Diesel Burner Parts, continued * Asterick denotes 24 volt model Aqua-Hot Motor Coach Heating System Parts Manual 06/02 Page 1-3

18 AQUA-HOT PARTS MANUAL See page 1-6 for part number details on items 104 through109. Diesel Burner Parts, continued Page 1-4 * Asterick denotes 24 volt model Aqua-Hot Motor Coach Heating System Parts Manual 06/02

19 Diesel Burner Parts, continued AQUA-HOT PARTS MANUAL 50 WPX Valve, Fuel Solenoid, 12 VDC, DBW , AH/HH/WH 50* WPX Valve, Fuel Solenoid, 24 VDC, DBW , AH/HH/WH 51 WPX Valve Kit, Fuel Solenoid, DBW , AH/HH/WH 52 WPX O-Ring, Fuel Solenoid Valve, DBW , AH/HH/WH 53 WPX Bolt, Electrode Clamp, DBW , AH/HH/WH 54 WPX Washer, Lock, Electrode Bolt, DBW , AH/HH/WH 55 WPX Clamp, Ignition Electrode, DBW , AH/HH/WH 56 WPX Electrode, Ignition, DBW , AH/HH/WH 58 WPX Screw, Flame Sensor, DBW , AH/HH/WH 59 WPX A Sensor, Flame, DBW , AH/HH/WH 60 WPX Clip, Retaining, Photo Disc, DBW , AH/HH/WH 61 WPX A Photo Disc, DBW-2010, AH/HH/WH 62 WPX A Nozzle, Fuel, 0.35 GPH, DBW-2010, AH/HH/WH 65 WPX Pipe, Fuel, High Pressure, DBW , AH/HH/WH 66 WPX Bolt, Banjo, DBW , AH/HH/WH 67 WPX Gasket Ring, Copper, DBW , AH/HH/WH 68 WPX Pipe, Fuel Banjo, Supply, DBW-2010, AH/HH/WH 69 WPX Pipe, Fuel Banjo, Return, DBW-2010, AH/HH/WH 70 WPX Screw, Fastening, Fuel Pump, DBW , AH/HH/WH 71 WPX Washer, Lock, Fuel Pump Screw, DBW , AH/HH/WH 72 WPX A Pump, Fuel, 10 Bar, DBW , AH/HH/WH 73 WPX Stand, Nozzle, DBW , AH/HH/WH 74 WPX Screw, Nozzle Stand Plate, DBW , AH/HH/WH 75 WPX Plate, Nozzle Stand, DBW-2010, AH/HH/WH 76 WPX Gear, Drive, Nylon, DBW , AH/HH/WH 77 WPX Snap Ring, Gear, DBW , AH/HH/WH * Asterick denotes 24 volt model Aqua-Hot Motor Coach Heating System Parts Manual 06/02 Page 1-5

20 AQUA-HOT PARTS MANUAL FULL HOT FULL COLD Control Unit A B C Internal Parts 90 WPX A Combustion Chamber, DBW-2010, AH/HH/WH 91 WPE A Burnerhead, Modified, VSI DBW-2010, 12 VDC, AH 91* WPE A Burnerhead, Modified, VSI DBW-2010, 24 VDC, AH 92 WPX Pin, Eye Bolt, DBW-2010, AH/HH/WH 93 WPX Bolt, Eye, DBW-2010, AH/HH/WH 94 WPX Nut, Eye Bolt, DBW 2010, AH/HH/WH 95 PLX Tank, Expansion, 5qt, AH 96 SME Cover, Thermostat Access, S.S., AH 97 ELE-L Thermostat, VDC Control, 190 F, Blue Dot, AH 98 ELE-L Thermostat, VDC High-Limit, 230 F, Black, AH 99 ELE Thermostat, VAC High-Limit, 230 F, White Dot, AH 100 ELE Thermostat, VAC Control, 198 F, Red Dot, AH 101 SME Cover, Element Access, S.S., AH 102 WPX Gauge, Adjustment, Electrode, DBW , AH/HH/WH 103 PLX Cap, Radiator, AH 104 PLX Fitting, Bulkhead, 1/4 X 1/4 (F)NPT, Brass, AH/HH 105 FLX-751-CVL Fitting, Valve, Fuel Check, 1/4 X 1/4 (M)NPT, AH/HH 106 FLX-FL1-022 Fitting, Elbow 90, 1/4 X 1/4 (F)NPT, Brass, AH 107 FLX Fitting, Steel, #6 (M)JIC X 1/4 (M)NPT, AH 108 FLE-FUL-200 Fuel Kit, w/fuel Line & Clamps, AH 109 FLE-FUL-100 Fuel Kit, Steel Fittings, AH/HH Page 1-6 * Asterick denotes 24 volt model Aqua-Hot Motor Coach Heating System Parts Manual 06/02

21 1/2 1/2 1/2 AQUA-HOT PARTS MANUAL / / Pump Parts 110 PLX-BV1-200 Valve, Ball, 1/2 (F)NPT, AH 111 PLE Copper, Manifold, Return, 3-Zone Assembly, AH 112 PLE Copper, Manifold, Supply, 3-Zone Assembly, AH 113 PLE B Copper, Assembly, Engine Supply, 1/2in, AH 114 PLE Copper, Assembly, Engine Return, 1/2in, AH 115 PLX-4A8-18R Valve Kit, Tempering, AH 116 PLX Valve, Pressure Relief, 125 PSI, AH/HH 117 PLX-A Valve, Elbow 90, Barb, 5/8 X 3/8 (M)NPT, Brass, AH 118 HDX Bolt, Hex, 1/4-20 X 1/2in, S.S., AH 119 SME Cover, VAC Access, S.S., AH 120 SME Bracket, S.S, Angle 90, Mounting Feet, AH 121 PLX Pump, BR-809 Circulation, 12 VDC, AH 121* PLX Pump, BR-809 Circulation, 24 VDC, AH 122 PLX-2A1-300 Valve, Check, 1/2 X 1/2 (F)NPT, Brass, AH/HH 123 HDE-100-8RT Strut, Pump Support Kit, AH 124 SME Bracket, Angle, Pump Support Kit, AH 125 PLX Fitting, Bulkhead, 1/2 X 1/2 (F)NPT, Brass, AH/HH 126 FLX-120-VS1 Filter, Fuel, System, 10 Micron, AH/HH 127 FLX-R12-TRA Filter, Fuel, Spin-On Element, 10 Micron, AH/HH * Asterick denotes 24 volt model Aqua-Hot Motor Coach Heating System Parts Manual 06/02 Page 1-7

22 AQUA-HOT PARTS MANUAL Bulkhead Parts 127 ELE-VS1-005 Harness, Bulkhead, AH 128 ELE-VS1-006 Harness, Circulation Pump, AH 129 ELE-VS1-007 Harness, B-Plug, AH 130 ELX-2E7-540 Element, Electric Heating, 120 VAC/1650 Watt, AH/HH 131 ELX-14F-634 Terminal Strip, 8-Position, AH 132 ELX-BB6-10A Fuse Block, AH 133 ELX Fuse, 15 Amp, Spade Type, AH 134 ELX Fuse, 10 Amp, Spade Type, AH 135 ELX-SR3-B05 Socket, Relay, Grey, AH 136 ELX-W1A-486 Relay, 12 VDC, AH 136* ELX-W1A-487 Relay, 24 VDC, AH 137 ELX-9P3-500 Clip, Support, Relay, AH Page 1-8 * Asterick denotes 24 volt model Aqua-Hot Motor Coach Heating System Parts Manual 06/02

23 AQUA-HOT PARTS MANUAL Motor Coach Heating Specialists Manufacturers and Distributors East Highway 52 Fort Lupton, Colorado Fax: Copyright 2002 Vehicle Systems, Inc. All rights reserved * Asterick denotes 24 volt model Aqua-Hot Motor Coach LTE-LMA-003 Heating System Parts Manual 06/02

24 Shop Manual Model Numbers AHE S -12 VDC AHE S - 24 VDC Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02

25 TABLE OF CONTENT ONTENTS Sections 1 Aqua-Hot Information 1.1 Aqua-Hot Component Overview 1.2 Aqua-Hot Identification Plate 2 Aqua-Hot Wiring Information 2.1 Wiring Diagram 2.2 Control / High-Limit Thermostat Wiring 3 Diesel-Burner Information 3.1 Diesel-Burner Component Overview 3.2 Operational Flow-Chart 3.3 Diesel-Burner Identification Plate 4 Diesel-Burner Wiring Information 4.1 Control Unit Wiring 5 Diesel-Burner Service, Maintenance, and Repair Information 5.1 General Maintenance 5.2 Detaching the Diesel-Burner Head 5.3 Flame Detection Photocell 5.4 Ignition Electrodes 5.5 Fuel Nozzle 5.6 Fuel Solenoid Valve 5.7 Fuel Pump 6 Troubleshooting 6.1 Troubleshooting Flow-Chart 7 Aqua-Hot Warranty Information 8 Parts List 9 Special Tools Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02

26 Hot Section 1: Aqua-Hot Information Overview 1.1 Aqua-Hot Component Overview Zone # C Supply Expansion Tank Zone # A Supply Zone # A Return Zone # B Return Zone # B Supply Zone # C Return Cold Fill / Radiator Cap Thermostat Access Panel VAC Service Input Zone Circulation Pump Engine Preheat Circulation Pump VAC Access Panel Fuse Block I.D Plates Diesel-Burner Head Engine Coolant Supply Diesel Fuel Supply Diesel Fuel Return Pressure-Relief Valve Hot Water Outlet (Domestic Water) Cold Water Inlet (Domestic Water) Engine Coolant Return Zone Relay #C Electric Heating Element Access Panel Diesel-Burner Control Mixer Unit Valve Zone Relay #A Zone Relay #B Figure 1 Page 1 Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02

27 Section 1: Aqua-Hot Information Aqua-Hot I.D. Plate 1.2 Aqua-Hot Identification Plate MODEL No. SERIAL No. AHE S The I.D. Plate is located on the right sidewall of heating unit, directly below the VAC Access Panel, see Figure 1. Install in strict compliance with local codes, NFPA 501c and manufacturer's instructions. For installation only in compartment completely closed off from living quarters and accessible only from the outdoors. Exhaust pipe must not terminate beneath the vehicle. Caution! Do not adjust the Heater's Tempering Valve. Tampering with the Tempering Valve can increase the risk of scald injury. Use copper electrical conductors only. Approved for use in recreational vehicles and in marine applications. Complies with the requirements of UL 307A and (USCG) CFR33. Serial Number Box Model Number Box 12 VDC/110 VAC 1650 W Fuel: Diesel 1 or 2 Firing rate: 50,000 btu/hr patent No. 5,025,985 and 5,067,652 PO BOX 7025 SALT LAKE CITY, UTAH Listing No MODEL No. SERIAL No. AHE S The lower portion of the I.D. Plate is located inside the heating unit to the right of the Electric Heating Element Access Panel, see Figure 1. Serial Number Box Figure 2 Model Number Box Page 2 Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02

28 Section 2: Aqua-H qua-hot Wiring Infor nformation Wiring Diagram 2.1 Wiring Diagram Zones (C) (B) (A) T- STAT T- STAT T- STAT Wiring Diagram Key ( ) Indicates Field Wiring Chassis Ground Engine Preheat Switch ( - ) Bedroom Thermostat ( - ) Bathroom Thermostat ( - ) Living Room Thermostat ( - ) (+) Control Switch ( - ) (+) Indicator Light ( - ) Brown Living Room Pump Green A-Zone Bathroom Pump Fresh Water Tank / Bay Pump Bedroom Pump B-Zone Red Blue Brown Power Post (+) Battery Connection A B C D E F Green Blue White Blue Red Green C-Zone 10A OPEN 10A 10A 10A 15A Ground Post (-) Battery Connection Engine Pump Yellow + Pumps + Fans B-1 B-4 Red Red Black Black White ( - ) (+) Living Room (A-Zone ) Cozy Heat Exchanger A-Zone Relay ( - ) (+) Bathroom (B-Zone ) Cozy Heat Exchanger ( - ) (+) Bedroom (C-Zone ) Cozy Heat Exchanger B-Zone Relay C-Zone Relay B-4 B-1 B-3 B-6 Figure 3 Page 3 Fresh Water Tank / Bay Whisper Heat Exchanger Blue ( - ) T- STAT (+) Orange Black Fresh Water Tank / Bay Thermostat (B-Zone ) C-2 Diesel-Burner C-Plug (8 Pin) Brown B-2 For Technical Support call Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02 Diesel-Burner B-Plug (6 Pin)

29 Thermostat Thermostat Thermostat Thermostat Thermostat Thermostat Thermostat Thermostat Thermostat Thermostat Thermostat Thermostat Section 2: Aqua-H qua-hot Wiring Infor nformation Control / High-Limit Thermostat Wiring 2.2 Control / High-Limit Thermostat Wiring Orange Wire Blue Wire VAC High-Limit Thermostat, 230 F White Dot 12-2 ROMEX Cable w/ground VAC Service Input / ROMEX Clamp "COMMON" White Wire to White ROMEX Wire VDC Control Thermostat, 190 F, Blue Dot Green Wire (Ground) Black Wire RED 110 Element Ground Post Aqua-Hot Junction Box Black Wire VAC Control Thermostat, 198 F, Red Dot "GROUND" Green Wire to ROMEX Copper Wire VDC High-Limit Thermostat, 230 F, Black Black Wire White Wire Purple Wire "120 VAC POWER SUPPLY" Black ROMEX Wire to "LOAD" Black Wire White Wire 120 VAC / 1650 Watt Electric Heating Element Figure 4 Page 4 Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02

30 Section 3: Diesel-Burner Information Overview 3.1 Diesel-Burner Component Overview 1. Control Unit 10. Combustion Chamber 2. Motor 11. Heat Exchanger 3. Ignition Coil 12. Exhaust Port 4. Clutch 13. Flame Detection Photocell 5. Combustion Air Fan 14. Fuel Pump 6. Fuel Solenoid Valve 15. Fuel Ports (Supply / Return) 7. Electrode Holder 16. Combustion Air Port (Intake) 8. Ignition Electrodes with Adjustable Shutter 9. Fuel Nozzle Figure 5 Page 5 Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02

31 Section 3: Diesel-Burner Information Diesel- Burner Operational Flow-Chart 3.2 Operational Flow-Chart ~ Reference Figure 5 for all numbers indicated inside parenthesis. (i.e #8). Operation sequence once the Aqua-Hot's Diesel-Burner Control Switch is turned ON. The Control Switch's indicator light will illuminate. The "MOTOR" (#2) (which turns the "COMBUSTION AIR FAN" (#5) and drives the "FUEL PUMP" (#14)) will begin to run. NOTE: If the Aqua-Hot's Coolant reservoir temperature is approximately 175 degrees Fahrenheit, or higher, the "MOTOR" (#2) will not operate. Only when the temperature has dropped below 175 degrees Fahrenheit will the "VDC CONTROL THERMOSTAT" (see Figure 4) allow the "MOTOR" (#2) to operate. Simultaneously the "IGNITION COIL" (#3) produces a High Voltage Spark across the "IGNITION ELECTRODES" (#8) which ignites the incoming Air / Fuel Once the ignited Air / Fuel mixture (FLAME) is observed by the "FLAME DETECTION PHOTOCELL" (#13), the "IGNITION COIL" (#3) will automatically switch OFF. The combustion process now continues to operate unassisted. The combustion process will continue to operate in this manner until: A.) The "VDC CONTROL THERMOSTAT", (see Figure 4) (which senses Coolant Temp.), reaches the preset temperature of approximately 190 degrees Fahrenheit. The "MOTOR" (#2) will continue to run for approximately three (3) additional minutes. This is called the "Purge-Cycle", which cools down the Heater's internal components and purges the "COMBUSTION CHAMBER" (#10) of any residual exhaust gases. NOTE: When the Aqua-Hot Diesel- Burner is switched OFF by the "VDC CONTROL THERMOSTAT" (see Figure 4): A.) The "MOTOR" (#2) will shut-off once the three (3) minute "Purge-Cycle" has expired. B.) The Aqua-Hot's Diesel- Burner will automatically turn back ON once the coolant temp. reaches the preset temperature of approximately 175 degrees Fahrenheit. After approximately seconds the "FUEL SOLENOID VALVE" (#6) opens and fuel is sprayed into the "COMBUSTION CHAMBER" (#10) through the "FUEL NOZZLE" (#9). B.) The Aqua-Hot's Diesel- Burner Control Switch is turned OFF. Once the Heater switches OFF, thermostatically or manually, the "FUEL SOLENOID VALVE" (#6) closes, which interrupts the supply of diesel fuel to the "FUEL NOZZLE" (#9). Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02 SUMMARY: The Aqua-Hot's Diesel-Burner is operational anytime the operator activates the Diesel-Burner Control Switch to the ON position. The Diesel-Burner will then automatically maintain the temperature of the coolant without any additional involvement from the operator. Page 6

32 Section 3: Diesel-Burner Information Diesel Burner I.D. Plate 3.3 Diesel-Burner Identification Plate Fabrikschild-Duplikat gultig nur zusammen mit Original Thermosysteme GmbH MADE IN GERMANY HEIZGERAT Typ DBW Spannung / El. Leistung 12 V / 60W Warmestrom 13,2 kw Brennstoff Diesel zul. Betriebsuberdruck 2 bar Prufzeichen Fabriknummer 1B Inbetriebnahmejahr Model Type Voltage / Wattage Fuel Type Serial Number (230410) Diesel-Burner I.D. Plate is located on the left side of the Diesel-Burner Head Diesel-Burner Head Figure 6 Page 7 Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02

33 Section 4: Diesel-B iesel-bur urner Wiring Infor nformation Control Unit Wiring 4.1 Control Unit Wiring ( + ) VDC Control Thermostat (Orange) ( + ) Indicator Light (Blue) ( - ) Battery (Brown) ( + ) Blower Motor (Black) ( - ) To Overheat Circuit And Solenoid Valve (Blue) ( + ) On / Off Switch With Low Voltage Protection (White) B-Plug C-Plug ( + ) To Ignition Coil (Yellow) ( + ) Battery (Red) ( - ) Indicator Light (Green) ( + ) From Normally Closed VDC Control Thermostat (White) ( + ) Flame Detector (Green) ( - ) For All Heater Components (Brown) Figure 7 Page 8 Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02

34 Section 5: Diesel-Burner Service, Maintenance, and Repair Information Upkeep 5.1 General Maintenance Monthly Check the Aqua-Hot's solution of water and antifreeze to ensure that it is at the proper level. Do this by visually checking the coolant level in the Aqua-Hot's Expansion Tank, see Figure 1. This should be checked only when the Aqua-Hot is at full operating temperature, HOT. Annually CAUTION: Before cleaning or servicing, disconnect all power supplies. It is ideal to have your Aqua-Hot tuned-up yearly. A tune-up should consist of a Fuel Nozzle and Fuel Filter replacement and a thorough cleaning of the Combustion Chamber, if necessary, see Figure 8. This simple tune-up will keep your Aqua-Hot running smoothly throughout the year. This annual tune-up will also allow service personnel to inspect for wear and tear of other components. CAUTION: Operating the Aqua-Hot s Diesel-Burner or the 120 VAC Electric Heating Element without the water and antifreeze solution will cause serious damage to the Heater. Fuel Nozzle Fuel Filter Combustion Chamber Figure 8 Page 9 Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02

35 Section 5: Diesel-B iesel-bur urner Ser ervice, Maintenance, and Repair Infor nformation Detaching Diesel-Burner Head 5.2 Detaching the Diesel-Burner Head Grommets Eye-Bolts and Nuts Blower Casing Figure 9 Diesel Fuel Supply Diesel Fuel Return Instructions For Detaching the Diesel-Burner Head from the Aqua-Hot CAUTION: Before detaching the Diesel-Burner Head, disconnect all power supplies. 1. Loosen the two Eye-Bolt Nuts and swing the Eye-Bolts out of the way. 2. With both hands, carefully pull the Diesel-Burner away from the Aqua- Hot, approximately 4-5 inches. Please note that you may have to lift the head slightly while pulling it away from the Aqua-Hot. 3. Rotate the head approximately 90 angular degrees to the right or until all the internal components are visible. NOTE: It may be necessary to disconnect the two RED wires, which are connected to pin #6 of the B-Zone relay, when rotating the head beyond 90 degrees, see Figure 3. CAUTION: When reattaching the Diesel-Burner Head to the Aqua-Hot, be sure to properly align the head and DO NOT over tighten the Eye-Bolt Nuts. An improper alignment and or an over tightening of the Eye-Bolt Nuts can cause damage to the Diesel-Burner Head's aluminum-cast housing (Blower Casing), see Figure 9. Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02 Page 10

36 Section 5: Diesel-B iesel-bur urner Ser ervice, Maintenance, and Repair Infor nformation Flame Detection Photocell 5.3 Flame Detection Photocell Flame Detection Photocell Green Wire Figure 10 Blue Wire Photo Disc Flame Detection Photocell Cleaning Notes For light dirt, dust and carbon deposits simply wipe off the Flame Detection Photocell with a soft cloth. Should heavy carbon deposits be present, completely remove the Flame Detection Photocell from the Photo Disc and clean with carburetor cleaner. Ignition Electrodes 5.4 Ignition Electrodes Note: Electrode Adjustment Gauge is located on the outside surface of the Diesel- Burner on the lefthand side. Electrode Adjustment Gauge Note: Once adjustment is complete, remove Electrode Adjustment Gauge and reattach to Diesel-Burner. Ignition Electrodes Figure 11 Adjustment gauge properly positioned Page 11 Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02

37 Section 5: Diesel-B iesel-bur urner Ser ervice, Maintenance, and Repair Infor nformation Fuel Nozzle 5.5 Fuel Nozzle Fuel Nozzle Fuel Nozzle Stand Figure 12 Note: When replacing the Fuel Nozzle, be sure to tighten the Nozzle, then loosen 1/4 turn and firmly retighten. This will establish a seated fit and avoid any leaks. Solenoid Valve 5.6 Fuel Solenoid Valve Electrical Terminals (+) (-) Fuel Solenoid Valve Fuel Solenoid Kit Figure 13 Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02 Page 12

38 Section 5: Diesel-B iesel-bur urner Ser ervice, Maintenance, and Repair Infor nformation Fuel Pump 5.7 Fuel Pump Fuel Pump Pressure Regulation (Adjustment) Note: Adjust fuel pressure to 145 PSI. (+) Clockwise rotation increases fuel pressure. (-) Counter Clockwise rotation decreases fuel pressure. Fuel Pressure Gauge Note: Fuel Pressure gauge replaces the Fuel Nozzle when adjusting fuel pressure. Figure 14 Page 13 Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02

39 Section 6: Troubleshooting Troubleshooting Flow-Chart 6.1 Troubleshooting Flow-Chart 1. Check indicator light bulb. Replace if necessary. Turn the Control Switch ON. Is the indicator light illuminated? No 2. Remove the Aqua-Hot's ACCESS COVER. 3. Check Aqua-Hot fuses (E & F) for continuity, see Figure 3. Replace if necessary. Yes 4. Check DC power supply at the "POWER POST" and "GROUND POST", see Figure Attempt heater restart. 1. Remove the Aqua- Hot's ACCESS COVER. 2. Check Aqua-Hot fuse (F) for continuity, see Figure 3. Replace if necessary. NOTE: The indicator light will illuminate for only 30 seconds if fuse (F) is blown (open circuit). No Is the Diesel- Burner's "MOTOR" (#2) operating? Yes 1. Remove the Aqua-Hot's ACCESS COVER. 2. Remove the "THERMOSTAT ACCESS PANEL", see Figure Check the Diesel-Burner's "VDC HIGH-LIMIT THERMOSTAT" for continuity, see Figure 4. NOTE: This Thermostat protects against overheating temperatures. 3. Attempt heater restart. 1. Replace Thermostat. Check the Diesel- Burner's "VDC CONTROL THERMOSTAT" (blue dot) for continuity, see Figure 4. Yes Is there continuity across the Thermostat? NOTE: Aqua-Hot operating temperature must be below 170 degrees Fahrenheit when checking the "VDC CONTROL THERMOSTAT" for continuity, see Figure 4. No Is there continuity across the Thermostat? No 1. Replace the Thermostat. 2. Attempt heater restart. 2. Attempt heater restart Yes Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02 Page 14

40 Section 6: Troubleshooting 1. Turn the Control Switch OFF. 2. Remove the fuel-line from the Aqua-Hot's "DIESEL FUEL RETURN" (see Figure 1) and place a short piece of fuel line in its place. 3. Put the opposite end of the fuel line in a container. Is the fuel flow consistent without air bubbles? No 1. Check for fuel leaks in the Diesel-Burner's "DIESEL FUEL SUPPLY" line, see Figure 9. Repair if necessary. 2. Check the Aqua-Hot's "FUEL FILTER" (see Figure 8) for clogging. Replace if necessary. 4. Place the probes of a DCmulti meter into plug locations, B-1 (+) and B-2 (-), of the Diesel- Burner's "CONTROL UNIT" (#1), see Figures 1 and 7. Also, measure the voltage across B-2 (-) and B-4 (+). 5. Turn the Control Switch ON. Yes 3. Reattach "DIESEL FUEL RETURN" line, see Figure Attempt heater restart. 1. Check the Control Switch's: 6. Observe the fuel flow. Flow should be consistent without air bubbles. A. wire connections. B. fuse (E) for continuity, see Figure Check the voltage level of the DC-multi meter. NOTE: Voltage level should be within 0.5 volts of the system's DC battery voltage. Does the DCmulti meter indicate acceptable system voltage? No 2. Check DC power supply wires and connections, see Figure Reattach "DIESEL FUEL RETURN" line, see Figure 1. Yes 4. Attempt heater restart. 1. Inspect the "FLAME DETECTION PHOTOCELL" (#13) (see Figure 10) for dust and or sooty carbon deposits. Clean if necessary. 2. Completely cover the "FLAME DETECTION PHOTOCELL" (#13) (see Figure 10) with a shop rag. 3. Turn the Control Switch ON. After approx. 20 seconds of operation a bright blue arc (spark) should appear across the "IGNITION ELECTRODES" (#8), see Figure Turn the Control Switch OFF. 2. Reattach "DIESEL FUEL RETURN" line, see Figure Detach the "DIESEL-BURNER HEAD" from the Aqua-Hot, see Figures 1 and Disconnect one of the wires from the "FUEL SOLENOID VALVE" (#6), see Figure 13. NOTE: Do not remove or cut any of the external wires attached to the "DIESEL-BURNER HEAD".! WARNINGS: 1. DO NOT attempt to restart the Aqua-Hot when the "DIESEL- BURNER HEAD" is detached. An open flame can result and cause serious personal injury. 2. To prevent a fire hazard, be sure to disconnect one of the "FUEL SOLENOID VALVE" (#6) (see Figure 13) wires. Page 15 Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02

41 Section 6: Troubleshooting Does a spark appear across the Ignition Electrodes? Yes No Within 15 seconds, after turning ON the Control Switch, disconnect one of the two wires from the "FLAME DETECTION PHOTOCELL" (#13) (blue or green), see Figure 10. A spark should now appear across the "IGNITION ELECTRODES" (#8), see Figure 11. Does a spark appear across the Ignition Electrodes? Remove shop rag from the "FLAME DETECTION PHOTOCELL" (#13) (see Figure 10), exposing it to a light source. The spark should disappear. Does a spark disappear after the Photocell is exposed to light? No 1. Turn the control switch OFF. Yes 2. Check "FLAME DETECTION PHOTOCELL" (#13) (See Figure 10) for proper operation by: Removing both wires from the Photocell and covering with a shop rag. When dark, Photocell wire leads should read 300,000 ohms, or greater, of electrical resistance. Remove shop rag and expose to light; electrical resistance should be 300 ohms or less. 1. Turn the Control Switch OFF. 2. Check "IGNITION COIL" (#3) for proper operation by: Removing C-plug from "CONTROL UNIT" (#1), see Figure 7. Apply DC power (+) to C-8 plug (yellow wire) and ground (-) to C-5 plug (brown wire). A spark should now appear across the "IGNITION ELECTRODES" (#8), see Figure 11. No 1. Replace "FLAME DETECTION PHOTOCELL" (#13), see Figure 10. No Does the Photocell operate properly? Yes 2. Reconnect "FUEL SOLENOID VALVE" (#6) (see Figure 13) wire. 3. Reattach "DIESEL-BURNER HEAD" (see Figure 9) and attempt heater restart. Yes 1. Replace "CONTROL UNIT" (#1), see Figure 7. Does the Ignition Coil operate properly? Cover "FLAME DETECTION PHOTOCELL" (#13) (see Figure 10) again with a shop rag. The spark should reappear and continue for approx. 15 seconds and then switch off. 2. Reconnect "FLAME DETECTION PHOTOCELL" (#13) (see Figure 10) wires and "FUEL SOLENOID VALVE" (#6) (see Figure 13) wire. 3. Reattach "DIESEL-BURNER HEAD" (see Figure 9) and attempt heater restart. 1. Replace "CONTROL UNIT" (#1), see Figure Reconnect "FLAME DETECTION PHOTOCELL" (#13) (see Figure 10) wires, "FUEL SOLENOID VALVE" (#6) (see Figure 13) wire and C-plug. Yes No 1. Replace "IGNITION COIL" (#3). 2. Reconnect "FLAME DETECTION PHOTOCELL" (#13) (see Figure 10) wire, "FUEL SOLENOID VALVE" (#6) (see Figure 13) wire and C-plug. 3. Reattach "DIESEL-BURNER HEAD" (see Figure 9) and attempt heater restart. 3. Reattach "DIESEL-BURNER HEAD" (see Figure 9) and attempt heater restart. Page 16 Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02

42 Section 6: Troubleshooting Does the spark reappear? Yes 1. Turn the Control Switch OFF. 2. Reconnect "FUEL SOLENOID VALVE" (#6) (see Figure 13) wire. 3. Remove both ignition wires from the "IGNITION ELECTRODES" (#8) see Figure 11) or connect a jumper wire across the Electrodes. No! CAUTION: To prevent a HIGH VOLTAGE shock and or a fire hazard, be sure to remove both "IGNITION ELECTRODES" (#8) (see Figure 11) (tape the ends and separate the wires) or connect a jumper wire across the Electrodes. 1. Turn the Control Switch OFF. 2. Replace "CONTROL UNIT" (#1), see Figure Turn the Control Switch ON. After approx. 20 seconds the "FUEL SOLENOID VALVE" (#6) (see Figure 13) should receive power from the "CONTROL UNIT" (#1), see Figure 7. A fine mist of fuel should appear from the "FUEL NOZZLE" (#9), see Figure Reconnect "FUEL SOLENOID VALVE" (#6) (see Figure 13) wire. 4. Reattach "DIESEL-BURNER HEAD" (see Figure 9) and attempt heater restart. 1. Replace "FUEL SOLENOID VALVE" (#6), see Figure 13. Yes Is a mist of fuel (cone-shaped) present? No 2. Retest fuel flow (without Fuel Nozzle). 3. Install "FUEL NOZZLE" (#9), see Figure Retest Fuel Nozzle spray pattern (fine mist of fuel present?). 5. Reconnect ignition wires to "IGNITION ELECTRODES" (#8) (see Figure 11) or remove jumper wire. 6. Reattach "DIESEL-BURNER HEAD" (see Figure 9) and attempt heater restart. 1. Turn the Control Switch OFF. 2. Reconnect ignition wires to "IGNITION ELECTRODES" (#8) (see Figure 11) or remove jumper wire. 3. Reattach "DIESEL-BURNER HEAD" (see Figure 9) and attempt heater restart. 1. Turn the Control Switch OFF. 2. Remove "FUEL NOZZLE" (#9), see Figure Turn the Control Switch ON. After approx. 20 seconds fuel should flow freely from the fuel nozzle port. No 1. Turn the Control Switch OFF. No Does the Solenoid Valve operate properly (click)? Yes 2. Check "FUEL SOLENOID VALVE" (#6) (see Figure 13) for proper operation by: Removing both wires from the Solenoid Valve and applying VDC power (+) and ground(-) to the Solenoid Valve electrical terminals. "FUEL SOLENOID VALVE" (#6) (see Figure 13) should click when VDC power is applied. No Yes Does fuel flow freely from the port? Page 17 Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02

43 Section 6: Troubleshooting 1. Check "FUEL SOLENOID VALVE" (#6) (see Figure 13) wires for continuity. Replace wires if necessary. 2. Replace "CONTROL UNIT" (#1) (see Figure 7) if wires indicate continuity. 3. Retest fuel flow (without Fuel Nozzle). 4. Install "FUEL NOZZLE" (#9), see Figure Retest Fuel Nozzle spray pattern (fine mist of fuel present?). 1. Turn the Control Switch OFF. 2. Replace "FUEL NOZZLE" (#9), see Figure Retest Fuel Nozzle spray pattern (fine mist of fuel present?). 4. Reconnect ignition wires to "IGNITION ELECTRODES" (#8) (see Figure 11) or remove jumper wire. 5. Reattach "DIESEL-BURNER HEAD" (see Figure 9) and attempt heater restart. 7. Reattach "DIESEL-BURNER HEAD" (see Figure 9) and attempt heater restart. NOTE: If an improper fuel spray is still observed (a normal spray pattern should be observed as a coned-shaped mist) the Diesel- Burner's "FUEL PUMP" (#14) (see Figure 14) should be calibrated for the proper fuel pressure setting. End of Troubleshooting Flow- Chart. For additional troubleshooting information please contact: Vehicle System's Service Dept. at Page 18 Aqua-Hot Hydronic Heating System Shop Manual REV-A 03/02